微槽结构单点金刚石飞切加工的切削力建模

超精密单点金刚石飞刀切削技术是一种比较新颖的微槽类结构加工方式。在飞切过程中,切削力是切削过程中重要的物理量,对加工后的表面质量、刀具磨损等有着直接影响。提出了一种基于直角微切削理论的动态微槽类结构飞切的力学模型,基于微切削理论,得到了前、后刀面切削力的理论模型。根据飞切的几何运动特征,建立了飞切过程中剪切角的计算模型,并根据单圈飞切实验得到了飞切过程中剪切面的变化规律。为了验证模型的正确性,采用不同切削参数进行了多圈重叠飞切实验,对切削力进行了测量和分析。实验得到的切削力大小和变化规律与理论模型计算得到的基本一致,证明了该切削力模型的有效性。

Cutting Force Model for Fabrication of Micro-Grooves by Single Point Diamond Flycutting

Ultra-precision single point diamond flycutting is a novel method to manufacture the microstructures with grooves. In the flycutting process, the cutting force is an important physical quantity. It is tightly associated with cutting quality and tool wearing. To develop the cutting regularity, a flycutting force model based on the theory of orthogonal microcutting was presented. The cutting force model on rake and flank face is achieved. The shear angle in flycutting process is analyzed based on the kinematical regularity. The value of the shear angle in specific processing parameters is achieved by single-turn flycutting experiments. To verify the flycutting force model, overlapping flycutting experiments with variant parameters are carried out. The validity of the force model is demonstrated with the accordance of experiments and theoretical analysis.